SmithyCNC 1240 Manual 2008 - Detroit Machine Toolsserver2.smithy.com/media/pdf/SmithyCNC 1240 Manual 2008.pdf · ... Protective Sheetmetal Cover, ... Our friendly service technicians

SMITHYCNC 1240 BED MILL

OPERATOR’S MANUAL

VERSION 1.1 2008

SmithyCNC 1240 BED MILL Operator’s Manual

SmithyCNC (Smithy Co.)170 Aprill Dr., Ann Arbor, MichiganUSA 48103

Toll Free Hotline: 1-800-476-4849Fax: 1-800-431-8892

International: 734-913-6700International Fax: 734-913-6663

www.smithycnc.com

Copyright © 2008 SmithyCNC & Smithy Co.

All rights reserved. No part of this manual may be reproduced or transmitted in any formby any means, electronic, mechanical, photocopying, recording, or otherwise, without priorwritten permission of Smithy Co.

For information on getting permission for reprints and excerpts, comments, or suggestions,contact [email protected]

While every precaution has been taken in the preparation of this manual, Smithy Co. shallhave any liability to any person or entity with respect to any loss or damage caused oralleged to be caused directly or indirectly by the instructions contained in this manual orby the computer software and hardware products described in it. Please see section onwarranty and safety precautions before operating the machine.

Printed and bound in the United States of America

TABLE OF CONTENTS

1 | INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Thank You . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Important Reminder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Suggestions or Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Customer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 | SMITHYCNC SYSTEM WARRANTY . . . . . . . . . . . . . . . . . . . . . . . 3

3 | GENERAL SAFETY GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Symbols Used in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 5Basic Points of Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Clothing & Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Safety Aspects Related to Tools Work Holding . . . . . . . . . . . . . . 8Safety Aspects Related to Maintenance . . . . . . . . . . . . . . . . . . . 9Safety Aspects Related to Workpiece . . . . . . . . . . . . . . . . . . . . . 10Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4 | INSTALLATION & SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Set-up Clearances & Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 11Power Requirments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

220 Plug Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Stand Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Moving from Pallet to Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Using a Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Using an Engine Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Attaching the Machine to the Stand. . . . . . . . . . . . . . . . . . . . . . . 19Attaching the X & Z Axis motors . . . . . . . . . . . . . . . . . . . . . . . . . . 19Installing Your Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5 | MECHANICAL COMPONENT IDENTIFICATION & FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

6 | MECHANICAL MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 24

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Ballscrews & Guidewats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Headstock & Spindle Bearings . . . . . . . . . . . . . . . . . . . . . . . 27

Period Maintenance Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Axis Bearing Adjustments/ Axis Backlash . . . . . . . . . . . . . . 27Y-Axis Ballscrew End Bearing Adjustment . . . . . . . . . . . . . 28Z-Axis Ballscrew End Bearing Adjustment . . . . . . . . . . . . . 28Adjustment of Gibs on the X & Y Axis Slides . . . . . . . . . . . . 29

Headstock to Table Realignment. . . . . . . . . . . . . . . . . . . . . . . . . . 30Linear Motion Guide & Bearing Maintenance . . . . . . . . . . . . . . 30

7 | TOOL HOLDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Tool Holding Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Installing the Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Removing the Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

8 | CNC-1240 BED MILL SPECIFICATIONS . . . . . . . . . . . . . . . . . . 34

9 | MACHINE PARTS DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Diagram 1: Protective Sheetmetal Cover, Millhead,

Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Diagram 2: Proximity Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Diagram 3: Mill-Drill Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Diagram 4: Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Diagram 5: Table & Bed Assembly . . . . . . . . . . . . . . . . . . . . . . . . 51

10 | ELECTRICAL DIAGRAM & PIN OUTS. . . . . . . . . . . . . . . . . . . . . 59

INTRODUCTION

THANK YOU FOR YOUR ORDER

Congratulations on your purchase of a SmithyCNC bed mill. With proper setup andmaintenance, your machine should provide many years of quality work and enjoyment.

This manual covers general instructions regarding machine set-up, operation,maintenanceand troubleshooting for SmithyCNC 1240 Bed Mills.

IMPORTANT

Before operating any SmithyCNC Bed Mill, this instruction manual and any accompanyinginstruction manuals must be read carefully. Instruction manuals should be kept in a safeplace where they are always easily accessible for reference during the operation of themachine.

While this manual has been compiled to give the general description and usage of the SmithyCNC 1240 Bed Mills, changes are possible due to continuous design anddevelopment efforts.

Remember safety comes above all else. Carefully, read, follow and understand the safetyinformation outline in chapter 3 of this manual and always let common sense be yourguide.

SUGGESTIONS OR COMMENTS

We are interested in any suggestions you might have to improve our products andservices. Feel free to contact us with your suggestions by phone or in writing.

If you have comments about this operator’s manual, or if you have a project you’d like toshare with other SmithyCNC owners, contact the SmithyCNC Company, P.O. Box 1517,Ann Arbor, MI 48106-1517. You can also e-mail [email protected] 24 hours a day.

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Or visit www.smithy.com 1

QUESTIONS

If you have questions not covered in the manual, please call our toll-free number:

1-800-476-4849 Our friendly service technicians are available Monday through Friday from 8:00 a.m. to5:00 p.m. Eastern Standard Time. You can also e-mail your questions 24 hours a day [email protected]. If you are calling from outside the United States, please dial 1-734-913-6700. You can also fax your questions to 734-913- 6663.

Don’t forget to check our website periodically, where we will post updates and revisionsto this manual as well troubleshooting techniques and technical advice.

CUSTOMER INFORMATION

Please record the information below about your SmithyCNC Bed Mill. Having thisinformation readily available will save time if you need to contact Smithy for questions,service, accessories, or replacement parts.

Model number: _____________________________________________

Serial Number: _____________________________________________

Purchase Date: _____________________________________________

Delivery Date: ______________________________________________

We look forward to a long working relationship with you, and thank you again for puttingyour trust in SmithyCNC.

SmithyCNC 1240 Operator’s Manual

Call Us Toll Free 1-800-476-48492

WARRANTY INFORMATION

SMITHYCNC SYSTEM WARRANTY

30 Day Trial Offer

Try a Smithy for 30 days. If, for any reason within that time, you decide to return yourSmithy, just call our Customer Service department at 1-800-476-4849. We will help youarrange shipping back to us. When we receive the machine back, we’ll refund your fullpurchase price. Please note: return shipping charges and any shipping damage fromimproper repacking is your responsibility.

Smithy Warranty

Smithy 3-in-1 and Dedicated Machines are warranted for two years (unless otherwisenoted)to the original purchaser against defects in materials and workmanship. During thattime, Smithy will replace any defective parts that are returned to our warehouse, free ofcharge. Upon receipt of the defective parts, Smithy technicians will arrange with you tosend replacement parts immediately. This warranty does not cover parts that are worn outthrough the negligence on the part of the operator nor does it cover consequentialdamages resulting from defects in material or workmanship.

SmithyCNC warrants its machines and control systems for a period of one (1) year to theoriginal purchaser from the date of purchase. If within one (1) year form the date ofpurchase a SmithyCNC machine and/or control system fails due to defect in material orworkmanship, SmithyCNC will at their choice repair and/or replace components with newor remanufactured parts free of charge.

(Some have asked why SmithyCNC machines have a shorter warranty period than Smithymanual machines. There are several reasons, but the greatest factor is that, on average,CNC automated machine tools, are operated a significantly greater number of hoursper day than the average manual machine. Also, by comparison, most of our competitorsselling benchtop CNC machines only offer a six (6) months warranty. Whereas SmithyCNCmachine have a full one (1) year warranty.)

Most warranty repairs and/or replacements are handled routinely, but sometimes requestfor warranty service many not be appropriate. This warranty does not apply to defects duedirectly or indirectly to misuse, abuse, negligence, accidents, repairs, or lack of routinemaintenance. This warranty is also void if the serial number of the machine or SmithyCNCcontrol system has been removed or has been altered or modified.

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In no event shall Smithy be liable for indirect, incidental or consequential damages for thesale or use of the product. This disclaimer applies to both during and after the term of thiswarranty.

We do not warrant or represent that the merchandise complies with the provisions of anylaw or acts unless Smithy Co. so warrants. In no event shall Smithy's liability under thiswarranty exceed the purchase price paid for the product. Legal actions brought againstSmithy Co. shall be tried in the State of Michigan, County of Washtenaw.

Smithy Co. shall in no event be liable for death, injuries to persons or property forincidental, contingent, special or consequential damages arising from the use of ourproducts.

This is Smithy Co.’s sole warranty and any and all warranties that may be implied by law,including any merchantability or fitness, for any particular purpose, are hereby limited tothe duration of this written warranty.

This warranty gives you specific legal rights, and you may also have other rights, whichvary from state to state. Some states do not allow the exclusion or limitation ofincidental or consequential damages, so the above limitation or exclusions may not applyto you.

Telephone Support (Service engineers are available 8 am to 5 pm EST):

Service and Parts

Tel No. 1-800-476-4849Fax No. 1-734-913-6663Email Address: [email protected]

Software and Programming Consultancy Services

In addition to our customary technical support for the machines and controls, we also pro-vide technical consulting support to our customers by providing engineering and G-codeprogramming services. The standard rate for these services is $28.00 per hour. Our princi-pal objective is to support you and to increase your productivity while reducing themachining cost. Give us a call for such support as and when required.

Tel No. 1-800-476-4849Fax No. 1-734-913-6663Email Address: [email protected]



GENERAL SAFETY GUIDELINES

OVERVIEW

General operational techniques and safety procedures will be outlined in this manual. Youwill note, for example, that all rotating parts, wherever feasible, are protected byspecially designed covers and shields. If the machine is operated in accordance with themanufacturers instructions, it will provide you with reliable service. However, withmachines of this nature, serious accidents may occur due to improper or carelessoperation. It is strongly recommended that you read this manual and accompanyingmanuals and understand thoroughly the contents of the manuals. Not every example ofimproper operation or unauthorized usage which may lead to malfunction or an accidentcan be anticipated. If a particular operation is not documented in this manual as anauthorized usage of the equipment, it should be assumed that it is an unauthorized orimproper usage with potential danger and should be avoided or the manufacturer shouldbe consulted before the actual use.

SAFETY

This machine is provided with various safely devices to protect the operator and themachine. However, these cannot cover all aspects of safety. Therefore, the operator mustthoroughly read and understand the content of this manual before the machine is turnedon and operated. The operator should also take into consideration these and other aspectsof safety related to his/her particular environmental conditions, materials and tools.

Safety Symbols Used in this Manual Three categories of safety guidelines have been used throughout this manual. Please takenote of these symbols and understand their meanings.

If this action is not avoided, it will cause permanent harmto your health, such as death or serious injury, and it mayalso cause permanent damage to your machine.

If this action is not avoided, it can cause potentialharm to your health, resulting serious injury, and haspotential to cause serious harm to your machine.

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DANGER

WARNING


If this action is not avoided, it may cause potential harm to your health, such as minor to moderate injury, and may also cause moderate harm to your machine.

Always observe the safety instructions inscribed on the safety nameplate fixed to themachine.

DO NOT remove or damage these name plates.

DO NOT attempt to operate or turn on the machine until you have read and understoodthe manuals supplied with the machine .

BASIC POINTS OF SAFETY

•There are high voltage terminals on the electrical control panel, motors, junction boxesand other equipment. DO NOT touch any of these components under any circumstances,when the power supply is ON.

•Make sure that all safety covers are fitted and electrical boxes are closed and securedbefore the power is switched to ON.

•If any components or safety covers are to be removed, first switch off or disconnect themain plug.

•Memorize the position of the EMERGENCY STOP BUTTON on the machine so that youcan press it immediately from any position in case of emergencies.

•DO NOT touch any of the switches accidently while the machine is in operations.

•DO NOT touch the tool holder while the machine is running.

•Under no circumstances, should you touch a rotating tool holder or workpiece while themachine is in operation mode.

•To prevent incorrect operation of the machine, carefully check the position of theswitches before operation.

•If in doubt, consult this manual or a SmithyCNC technician for advise and suggestions.

•Always unplug the main plug when the machine is not in use.

CAUTION

DANGER

WARNING



•If more than one person is operating the machine, DO NOT proceed to the next stepwithout informing the other operator(s) that you are about to do so.

•DO NOT modify the machine in any way that will affect safety.

•DO NOT subject the machine,control box, operator panel, or the electrical control panelto high voltage surge.

•DO NOT change the parameters or electrical setting values without good reason. If it isbecomes necessary to change the parameters or settings, first check with a Smithytechnician to assue that it is safe to do so, then make a note of the original values so thatit can be reset to that value, if necessary.

•DO NOT paint, soil, damage, modify, or remove any fo the safety nameplate. If the detailsbecome illegible or if the nameplate is lost, obtain a replacement from SmithyCNC andmount it in the original position.

•DO NOT remove any safety covers while the machine is in automatic operation mode.

•STOP all machine operations before cleaning the machine or any of the peripheralequipment. After a job has been completed, set up each part of the machine so that it isready to be used for the next series of operations.

CLOTHING & SAFETY

•Tie back long hair to prevent entangling with rotary tools.

•Wear safety equipment whenever possible.

•Always wear a protective mask when machining Magnesium alloys.

•Never wear loose or baggy clothes.

•DO NOT operate the machine while under the influence of drugs or alcohol.

•DO NOT operate the machine if you suffer from dizziness.

•Always use gloves when loading or unloading workpieces or tools and when removingchips from the work area to protect your hands from sharp chips and burns caused by heatgenerated during machining.

CAUTION

DANGER

General Safety Guidelines


•Close all covers and junction boxes before running the machine.

•Check all electrical cables for damage to prevent electrical shock.

•DO NOT handle coolant with bare hands to avoid irritation.

•Always use wire rope or slings as per standards, suitable for the load to be supported.

•DO NOT remove or adjust switches to increase axis travel beyond the machinespecifications.

•DO NOT wipe the workpiece or clear away chips with your hand or with a rag while thespindle is in operation.

•DO NOT allow chips to accumulate in the work envelope.

•Warm up the spindle and axis motion before running the machine in automatic mode.

•DO NOT operate the keyboard or operation panel switches when wearing gloves.

•DO NOT disconnect the main power cable without switching off the CNC and PCconnections.

SAFETY ASPECTS RELATED TO TOOLS & WORK HOLDING

•Always use proper cutting tools and work holding clamps suitable for the work andwithin the specifications of the machine.

•DO NOT stall the machine during cutting due to improper feed and depth of cut suitablefor the workpiece material.

•DO NOT operate the spindle above the rated speed of the accessories mounted in it suchas tool holders.

WARNING

CAUTION

WARNING



•Replace worn tools as soon as they are identified.

•Take care not to place any part of your bocy in the machine pinching areas.

•Make sure that the tool length to diameter ratio is proper to minimize vibration due toexcessive overhang conditions.

•Make sure the drawbar and the tool holders are tightened to the proper cutting conditionsbefore actual cutting operations.

SAFETY ASPECTS RELATED TO MAINTENANCE

• Always disconnect the power to the machine before carrying out any maintenance work.

•After the power has been switched off for a minimum of 60 minutes, check voltage witha multimeter or equivalent to make sure that there is no residual voltage.

•Maintenance of electrical and mechanical components should only be carried out byindividuals with working knowledge of the machine tool.

•DO NOT remove or modify switches.

•Clean the machine areas after the maintenance is completed.

•DO NOT use compressed air to clean the machines.

CAUTION

DANGER

WARNING

CAUTION

General Safety Guidelines


SAFETY ASPECTS RELATED TO THE WORKPLACE

•Always provide sufficient work space around the machine and peripheral equipment.

•Protect all cables from being damaged by cutting chips.

SAFETY EQUIPMENT

This machine is provided with various mechanical and electiracl safety devices to protectthe operator and the machine. The safety devices include interlock devices and emergencystop switches. However, it is absolutely recommended and necessary that the operatorfamiliarizes himself with the instruction manual of the machine before operating themachine. The manufacturer emphasizes that it is the sole responsibility of the operator toensure that all operations using the SmithyCNC bed mill are carried out in completely safemanner.

Neither the manufacturer nor its representative or dealers can assume responsibility forany mishaps, damage or personal injury which may occur as a result of improperoperation or from failure to observe the safety precautions mentioned in this manual.

WARNING



INSTALLATION & SET-UP

SET-UP CLEARANCES & CONDITIONS

When considering the permanent location for your SmithyCNC bed mill the followingshould be taken into consideration:

•The machine should be installed on a flat surface so that the machine does not rock orslide during operation.

•This location should be considered the machine’s permanent location for your machine.If you need to move it, remove it from the stand first.

•Make sure your stand is level prior to placing the machine on the stand. Improperinstallation and an unleveled machine can cause both numerical error and loss of precisionin your machining operation.

•The maximum temperature of your shop or working environment should not exceed125 ºF.

•Humidity levels should not exceed 80%.

•Set up the bed mill stand so you have plenty of working space. Leave at least 3 to 4 feetof clearance on the operating side of the machine. Note the suggested clearances of theother sides of the machine in table 4.1.

Figure 4.1 Set-up Clearances

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Table 4.1 Clearance Dimensions

POWER REQUIREMENTS

Table 4-2. Power Requirements

220 Plug Configuration

The power cord/plug that is supplied with the SmithyCNC EZ-TrolSystem and SmithyCNC PC Control option is a 220 volt NEMA 6- 15Pplug. This plug will fit into a 220 volt NEMA 6-15R or 6-20R receptacle.

NOTE: Smithy recommends that you run your machine on a dedicated 20 amp breaker.

STAND REQUIREMENTS

You will need a stand that is capable of supporting the weight of your machine plus themaximum allowable workpiece depending on your bed mill. (Please refer to thespecifications chart for the bed mill that you ordered to obtain this specification.) You willalso need to add into this figure additional weight for work holding devices, cutters andcoolant. A good rule is to build a stand that can support 5 to 6 times the weight of themachine without any appreciable, permanent deformation. The benchtop should be rigid,level and well-supported. If you purchased one of the optional bed mill stands availablefrom Smithy, these stands have been designed to support the weight of the specifiedmachine.

Your work bench should be located in a vibration-free area with a floor that is designed tosupport the full weight of the bench, machine, accessories, and materials.

If you purchased the optional Smithy Stand (Item 80-040 for the CN-1240 Mill then theholes for mounting your machine are pre-drilled and tapped. If you are making your own stand use the bolt pattern below.

NOTE: The mounting holes in the base of the machine are 10 mm.

A Dimension B Dimension C Dimension D Dimension

CNC 1240 Mill 83 in2110 mm

20 in500 mm

67 in1700 mm

81 in1700 mm

Voltage Amps Amps

CNC 1240 Mill 220 15 Single



Figure 4.3 Bolt Hole Pattern

SmithyCNC strongly discourages the use of casters or wheels on metalworking machine stands.The weight of the machine could result in the stand tipping while being moved. Once the machineis mounted, consider your work bench to be permanent. If you must move the machine, firstremove it from the bench.

LEVELING

Before any machining of the workpiece is done, it is crucial to level your machine for bestresults.

Step 1: Find a relatively flat place for the installation of the machine and place themachine stand in this spot taking note of the suggested clearances in table 4.1.

Figure 4.4 Level Shown parallel to the Y-Axis

DANGER

Installation & Set-up


Step 2: Position the X & Y axes slides as close to the mid-stroke position as possible. TheX & Y axes can be repositioned manually with the knurled wheels at the end of the axesscrews. (For leveling purposes, position of the Z axis is not as critical as the X & Y Axesslides.)

Step 3: Make sure your stand’s feet or leveling pads are touching the ground at the sametime. If not, adjust the feet to make sure the machine stand does not physically rock.

Step 4: Once all the feet or leveling pads are touching the ground and the machine is notrocking, adjust the middle two feet (on both sides of the machine) off the ground by about1/4 inch while the front and rear feet are on the ground.

NOTE: Pictures shown in this document are assuming you have purchased the optionalmachine stand with your CNC bed mill. If you have constructed your own stand, adapt this process for your stand.

Figure 4.5 Adjusting Stand Leveling Pads

Step 5: Place a machinist level on the mill table, parallel to the Y-axis. If the level bubbleis not in the center of the scale, adjust the left and right side feet up or down to bring thebubble in the center (i.e you are tilting the machine sideways about the Y axis of themachine.)

Step 6: Now, place the level parallel with the X-Axis. If it is not in the center of the scale,adjust the feet at the front and rear of the machine to bring the bubble to the center. (i.eYou are tilting the machine front to back about the X axis of the machine.)

Step 7: Keep the levels in place, drive the middle feet to the ground and make sure thebubble position does not change.

Step 8: Once both adjustments are completed, reposition the slides several times andreposition the slides in the middle stokes. (NOTE: This is done after you have hooked thecontrol system to your bed mill.)

Step 9: Check to confirm that the machine is still level by repeating steps 5 and 6. If themachine appears to be unlevel, repeat steps 2-7.

NOTE: This leveling procedure should be rechecked every 6 months to ensure machineleveling has not changed due to machine operation.



MOVING FROM PALLET TO STAND

There are four bolts securing the machine to the pallet. Use an adjustable wrench toremove nuts located on the machine pads. Once the nuts have been removed, tap thescrews through the casting and pallet if they didn’t fall through when removing the nuts.

Figure 4.6 Remove bolts from the machine base pads

Use tin snips to cut the metal bands securing the milling head in place. Remember thebands are under tension. Wear eye protection and gloves when cutting the bands.

Using a Forklift to Remove the Machine From the Pallet

Step 1: Use appropriately sized chains or tow straps when lifting your machine from thepallet. (Lifting capacity should be three times the weight of the object you are lifting.) Inthe diagram to the right we have chosen to use tow straps. These instructions are writtenfor that application. If you are using a chain instead, please adapt the attachment methodaccordingly.

Figure 4.7 Lifting Point in Column Base

NOTE: Before utilizing the lifting straps,examine them for tears or fraying that mightreduce the lifting capacity.

Step 2: Attach a 5/8” clevis to the two eye hooks located on the base of the machinetoward the operator’s side. (Eye hooks have a rough 1” diameter opening and are 1/2”thick.)

CAUTION



Step 3: Place an appropriate size rod through the lifting hole in the base of the column atthe back of the machine. See Figure 4.7.

Step 4: Place an end of the rod through one loop of the a tow strap.

Step 5: Clip the other end of the tow strap into the clevis/eye hook at the front of themachine. Be certain to secure the clevis before lifting.

Figure 4.8 Close up lifting strap, clevis and eye hook

Figure 4.9 Moving with a Forklift

Step 6: Repeat step 5 with another tow strap on the opposite side of the machine.

Step 7: Slide the tow straps over the forks and slowly raise the machine from the pallet.Before raising the machine high enough to place on the machine stand, check to make surethe machine is relatively level. If it does not appear level, lower the machine back to thepallet and adjust the tow straps so that the machine is balanced.



Figure 4.10 Engine Hoist Spreader correctly positioned for lifting SmithyCNC Mill

Step 8: Now that the machine is relatively level, raise the machine so that it is hovering,no more then 6-10 inches, over the machine stand.

Step 9: Using a straight rod (all-thread works well) to align the holes in the base of themachine to the holes in the stand. Align one corner on the front and one on the back.

Step 10: Once the holes in the machine are aligned with holes in the stand, slowly lowerthe machine into position on the stand.

Step 11: Secure the machine to the stand . (See the section in this document, securingmachine to the stand.)

Figure 4.11Chain Hook Up when using an engine hoist



Using an engine hoist to remove the machine from the pallet

Figure 14.12 Lifting with an engine hoist

Step 1: Using an engine hoist requires 2, 6 feet pieces of chain and 4 clevis pins largeenough to attach the links of the chain that you are using together. Remember to selectchain that is rated for lifting the weight of your machine.

NOTE: If you are renting an engine hoist make sure you are given the cradle/spreaderplate that attaches to the arm of the engine hoist.

Step 2: Attach a clevis to each of the two eye hooks located on the base of the machinetoward the operator’s side.

Step 3: Place an appropriate sized rod through the lifting hole in the base of the columnat the back of the machine.

Step 4: Position the cradle/spreader so that the chains are hanging on either side of themillhead. Once the plate is attached to the hoist it should hang between the millhead drivemotor and the Z-axis drive motor.

Step 5: Place the chain around the rod extruding from the back of the casting so that thereis enough chain to attach one end to the clevis which is locked into the eye hook at thefront of the machine.

Step 6: Attach the section of chain circling the bar extruding through the casting as wellas the section of chain attached to the eyehook, to the chains hanging from the hoistspreader. Note: Before lifting the machine, check the chains to see if they will be pushingagainst any sheet metal part. If the chains are rubbing or pushing against any sheet metalparts, reposition the chains in order to prevent damage. It may be helpful to open themillhead motor door before attaching the chains to the hoist spreader.

Step 7: Repeat step 5 and 6 on the other side.



Step 8: Attach the hoist spreader to the arm of the engine hoist if you have not done soalready, and slowly raise the machine from the pallet. Check to make sure that the machineis relatively balanced between the front and back of the machine. If it is leaning too far tothe front or the back, lower the machine back to the pallet and reposition the chains toachieve a better balance.

Step 9: Now that the machine is relatively balanced, raise the machine so that it ishovering over the machine stand.

Step 10: Using a straight rod (all- thread works well) align the holes in the base of themachine to the holes in the stand. Aligning one corner on the front and one on the back.

Step 11: Once the holes in the machine are aligned with holes in the stand, slowly lowerthe machine into position on the stand.

Step 12: Secure the machine to the stand . (See the section in this document, securingmachine to the stand.)

ATTACHING THE MACHINE TO THE STAND

Now that your machine is in place, it is important to properly secure it to your machinestand. If you purchased a stand from Smithy, the holes in the stand are pre-drilled andtapped. If you make your own stand, please refer to the bolt pattern at the end of thisdocument. These instructions assume that you have assembled your stand per the manu-facturers instructions.

Step 1: Once the holes in the base of the machine are aligned with those in the stand,secure the machine to the stand with the bolts provided with your Smithy stand.

Step 2: If you have ordered the Kool-Catch Coolant Containment system with yourmachine, please follow the assembly instructions included with the Kool-Catch system.

ATTACHING THE X & Z AXIS MOTORS

The Z and X-Axes motors have been removed for shipping. Once the machine has beensecured to the stand, re-attach the motors with the provided cap screws and couplings.Attach the cable leading out of the junction box to the motor.

INSTALLING YOUR CONTROL BOX

Now that your machine has been set-up, you are ready to install your control system. If youpurchased a SmithyCNC EZ-Trol system or PC Ready System, please refer to thedocumentation sent with your control. If you have purchased the base machine, we havesupplied you with the a set plugs that match the sockets on the junction box of theSmithyCNC bed mill that you purchased. You will be able to use these to wire your controlsystem of choice to your bed mill. Please reference chapter of this manual for pin-outinformation.



MECHANICAL COMPONENT IDENTIFICATION& FUNCTIONS

OVERVIEWThis chapter will help you to familiarize yourself with the major mechanical componentsand functions of your machine.

Figure 5.1 CNC 1240 Bed Mill Front View

1. Drawbar - The drawbar supports and “draws” tooling into the R-8 spindle of the CNC-1240 Bed Mill. The function of the drawbar is to locate the tool holder accurately inrelationship to the main spindle taper. The clamping and unclamping of the tools isachieved by the manual actuation of the drawbar system. (This is not visible from thepicture.)

2. Work Light - The work light is controlled with the Smithy EZ-Trol system. Please notethis is an on/off function only.

5


3. Emergency Stop Button - Located at the bottom left side of the mill head. Press thisbutton to stop movement of the slides and the mill spindle.

4. Gib Adjustment Screws - The CNC-1240 have a series of gib adjustment screws alongthe operator side of the saddle. These screws press a metal plate (the gib) to the ways ofthe saddle, increasing or decreasing the tension when moving the cross-slide assembly.Before adjusting the gibs, make sure they are well lubricated to achieve the desired result.(Reference chapter 6 for details.)

5. X-Axis Stepper Motor - The CNC-1240 mill is equipped with X, Y and Z axes steppermotors. This X-Axis stepper motor provides power for table movement along the X-Axis.See the machines specifications for motor sizes.

6. Lifting Eye Hooks - There are two lifting eye hooks located on the operator’s side ofthe machine. Use these eye hooks in conjunction with a chain or tow ropes to help moveyour machine from the shipping pallet to a stand.

7. Saddle - The mill table is supported by the saddle along the Y-Axis.

8. Mill Table - The mill table supports your work piece and work holding devices. Ittravels along the X & Y axes via ballscrews Both the CNC-1240 Mill have 5/8” T-Slots.

9. Motor Cover - The motor is protected by a sheet metal cover. The motor is easilyaccessible by turning the knurled knob on the right side of the cover. This cover shouldremain closed while the machine is in operation

Figure 5.2 CNC 1240 Bed Mill Side View

10. Spindle Drive Motor - The fan cooled spindle drive motor is located behind themotor cover.

Mechanical Component Indentification & Functions


11. Compressed Nitrogen Gas Cylinder - The CNC-1240 mill use a counter balancecylinder to counter the weight of the Z-Axis assembly.

12. Drive Belt - The drive belt for the motor is located behind the the motor cover. Themotor cover must be removed to replace or tension the belt. (Not visable in diagram.)

13. Head Rotation Locks Bolts - There are two bolts, one on either side of the mill headthat when loosened, allow the operator to rotate the millhead between 0 and 90 degrees ineither direction.

14. Spindle with R-8 nose taper - The CNC -1240 utilizes a spindle with an R-8 taper nosefor supporting and locating work holding tools. Any standard tool holding equivalent to theR-8 specifications can be mounted on the spindle with suitable adapters.

15. Bellows - The Y-Axis ballscrew is protected from chips and coolant by industrialbellows.

16. Mounting Points - There are six mounting points on the CNC-1240 Bed Mill. Themounting points are M10 holes located at each corner of the machine and one in themiddle of each side of the machine. Make sure that your machine is properly mountedbefore operating it.

17. Proximity Switches - A switch is located on each axis of travel. These switches arethe mechanical end position limits and they also are used to home the slides.

18. Proximity Switch Covers - The proximity switches on the CNC-1240 bed mill isprotected from coolant and chips with removable sheet metal cover.

19. Bed & Column - The bed and the column are a box type construction made of highquality grade 25 cast iron. They are designed for high rigidity with suitable cross sectionand ribs for reinforcement. Proper casting treatment is given to relieve the castings of anyundue stress before assembly and machining is done. The X-axis, Y-axis and Z-axis slidecomponents including the headstock assembly and table are mounted on the same baseand column structure.

20. Lifting Point - This lifting point is used in conjunction with the lifting eyehooks. Runan adequately sized bar through this point and attach tow ropes or chains to the bar toassist in the mechanical lifting process.

21. One Shot Lubrication System - The one shot or single stroke lubrication system islocated on the left side of the machine. The dovetail ways, ball nuts and liner bearings arelubricated when the lubrication system is activated. To be sure that enough lubrication isprovided, a minimum of two pumps is recommended and it is also advisable to visuallycheck the lubrication delivery on the lubed surfaces. Lubrication is very important formachine tools since it greatly affects machine life. Use only recommended lubrication oilswhich are clean and free from foreign matter. Follow the maintenance scheduled in thismanual. (Reference chapter 6.)

22. Bearing Guideway System - The millhead travels along the Z-Axis which is equippedwith the a linear bearing guideway system.



Figure 5.3 CNC 1240 Bed Mill back view

23. Lubrication Distribution Block - The shielded metal lines of the lubrication systemintersect at this block to deliver lubrication to the various parts of your CNC- 1240 BedMill.

24. Z-Axis Stepper Motor - This motor drives the Z-Axis of the machine and providesmotion of the head along the Z-Axis linear guideway.

25. Variable Frequency Drive - This is the drive for the main spindle motor.

26. Junction Box - The control system is connected to the machine via this junction box.

27. Y-Axis Stepper Motor - This motor drives the table along the dovetail ways of the Y-Axis.

Mechanical Component Indentification & Functions


MECHANICAL MAINTENANCE

MAINTENANCE SCHEDULE

Maintaining your machine as per the schedule documented in this manual will helpprolong the life of the machine and aid in the production of precision workpieces. It shouldbe noted that the maintenance schedules listed herein, are intended to be used as a guide.The enviroment and working conditions of your shop should be taken into consideration.

Daily Maintenance

Perform these maintenance tasks at the beginning and at the end of work.

Table 6.1 Daily Maintenance Table

6

AREA OFMAINTENANCE MAINTENANCE TASK HOW OFTEN

Lubrication System

• Check for oil level• Pressure build up during hand pumping• Check for distribution film of oil on all

sliding surfaces• Check for Leaks

At the start of work

Cutting Tools & ToolHolders

• Tighten the drawbar• Tighten work holding devices At the start of work

Coolant Level(Optional) • Check for level At the start of work

Machine Work Area • Check for leakage and cleanlinessAt the start & end of

work

Cleaning

• Clean the work holding devices• Clean guards• Clean machine• Clean Trays

At the start & end ofwork

External Wiring &Cables

• Check fit of cable connections• Check for damaged cable At the start of work

Machine GeneralCondition

• Check entire machien for loose or missing fasteners At the start of work

Spindle • Clean the spindle taper At the start of work


Periodic Maintenance

Perform these maintenance tasks as per the schedule below.

Table 6.2 Period Maintenance Table

*Additional instructions given.

AREA OF MAINTENANCE MAINTENANCE TASK HOW OFTEN

MECHANICAL

Axes Backlash • Check and compensate of necessary 6 months

Ball Screw Guards • Check condition 6 months or replace as necessary

Drive Belt • Check condition• Check tension

6 months or replace as necessary

Gib Adjustments* • Check table motion for fish tailing movement & adjust. Follow instructions. 6 months

Machine Base/ Table • Check for level & mounting bolt loosening 6 months

Tool Holder/ Drawbar • Check for breakage & thread damage 1 month

ELECTRICAL

Electrical Cabinets • Check for cleanliness• Check & secure any loose connections 3 months

Electrical Elements • Check for proper working of push button switches 3 months

Proximity Switches • Check for proper operations 3 months

Motors • Check for condition & testing 1 month

Mechanical Maintenance


Lubrication System

This section covers the lubrication of your machine. There are two primary areas oflubrication: areas lubricated by the single stroke lube system and the life greased bearings.

Remember, proper lubrication is very important. It greatly affects the performance andlongevity of your machine. If a the machine is operated without supplying the lubricatingoil, it will cause seizure of the sliding sufaces. Before opearting, visually inspect the oil onthe actual machine surfaces.

Use only recommended lubrication oils which are clean and free from foreign matter.Periodically clean the tank and strainers/filters, if provided, inspect the equipment'sfunctioning or lube supply pipes for damaged to ensure optimum machine operation.

Table 6.3 Lubrication Grade Table

Ballscrews and Guideways

The ballscrews, liner guidways and dovetail slides are lubricated by the single stokelubrication system. Follow the lubrication schedule in table 6.1. When lubridating thelinear guideway and dovetail slide, pull the lever of the one shotlube system away anddown from the machine. The number of pumps required will depend on your shopenvironment. Enough pumps should be administered until a thin layer of lubrication ispresent on the slides.

CAUTION

CAUTION

LUBRICATING POINTS LUBRICATING SYSTEM & RECOMMENDED OIL GRADE QUANTITY

Headstock Bearings GreaseKluber Isoflex BU-15 Life Grease

Ballscrews & Guideways Manual One Shot LubricationMobil-1 1 Liter

Quill & Ballscrew Bearings

GreaseKluber Isoflex NBU-15 Life Grease



Headstock & Spindle Bearings

The bearings are of a precision class of accuracy. The spindle bearings are lubricated forlife with high grade grease, such as Kluber Isoflex NBU-15. This grease maintains itslubrication properties at both low and high temperatures (- 70º F to 120º F). There is nonecessary lubrication to these bearings.

If the spindle starts making abnormal noises or gets very warm above (120º F), check fordamage of the spindle bearings after stopping the machine completely. The spindle shouldbe warmed up for approximately 15-20 minutes when the machine has been stopped for along period (for example 5 or more days).

PERIOD MAINTENANCE TASKS

Axis Bearing Adjustment/Axis Backlash

Backlash is the amount of movement the screw makes before the table engages. There area number of signs that may indicate that there is excessive backlash with your system:

• Rough/uneven surface finishes • Dimension inaccuracies • Table shakes under machining force

Even if none of these signs are present, it is recommended to check for backlashcompensation every 3-6 months depending on your usage of the machine. Please note,SmithyCNC EZ-Trol software has provisions for compensating for backlash within theprogram. This section of the manual is addressing mechanical backlash compensation.There are three main mechanical reason for backlash:

1. Pre-loaded ball nut is damaged and is causing axial play between the nut and the screw.If the ball nut is damage, the only solution to this is to replace the ballscrew and ball nutassembly.

2. The end support bearings are damaged. If you find that the end bearings are damaged,follow the procedure below for replacing the bearings.

3. The ball nut mounting screws #70 on diagram 5, page 8-16 of this manual, are loose. Inthis case move the table to the end of the stroke so that the nut mounting screws #70 and#26 are accessible. Tighten the bolts and make sure the bolts or housing threads are notdamaged before tightening.

4. The end bearing tightening nut is loose. Follow step 6 and 7 in the following procedureto tighten the bearings whenever required.

CAUTION



Y -Axis Ballscrew End Bearing Adjustment

For this procedure, you will need to refer to diagram 5 of chapter 8 of this manual.

Step 1: Remove axis motor.

Step 2: Detach bellows from saddle (Reference diagram number 5)

Step 3: Loosen the part#28 and 29 to remove the bearing housing #20. Loosen the endbearing nuts first. Remove the damaged bearing from the housing and ball screw.

Step 4: Check the opposed pair of angular contact bearings for damage. Make sure thebearings are not damaged or the housing of the bearing ID seating are not heavily scouredor damaged. If the bearings are damaged, acquire the new set of bearings for replacement.Also ensure the new set of bearings are packed with proper amount and type of greasebefore tightening. (See chapter 6 for lubrication specifications.)

Step 5: Install the inner bearing #30 first on the ballscrew, making sure the bearingorientation is the same as the original mounting direction.

Step 6: Install bearing housing #20 square with the ballscrew axis, making sure thebearing housing #20 is securely positioned with part numbers 28 and 29.

Step 7: Install bearing #21 from the outside of the housing, making sure the bearingorientation is the same as the original mounting direction. The bearing contact angle’scenter lines for these two bearings should be oppsed (in XFashion) to each other whenmounted.

Step 8: Tightened the first nut #25 (closer to the housing/bearing) to tighten the bearingsagainst the housing. Loosen the nut and re-tighten again to position the bearing properly.Install the second jam nut #25 to secure the first nut also.

Step 9: Rotate the screw manually to ensure the motion of the screw is smooth anduniform and the bearings are not creating any stop and go motion or are completelyjammed.

Z-Axis Ballscrew End Bearing Adjustment

For this procedure, you will need to refer to diagram 4 on chapter 8 of this manual.

Step 1: Remove axis motor.

Step 2: To replace the damaged bearings, loosen the part #9 to remove the bearinghousing #8. Loosen the end bearing nuts first. Remove the damaged bearing from thehousing #8 and ball screw #25.

Step 3: Check the opposed pair of angular contact bearings for damage. Make sure thebearings are not damaged or the housing of the bearing ID seating are not heavily scouredor damaged. If the bearings are damaged, acquire a new set of bearings for replacement.Also ensure the new set of bearings are packed with proper amount and type of grease



before tightening. (See chapter 6 for lubrication specifications.)

Step 4: Install the set of bearings #24 first on the ball screw. Make sure the bearingorientation is same as the original mounting direction. The bearing contact angle's centerlines for these two bearings should be opposed (in X-fashion) to each other whenmounted.

Step 5: Install the bearing housing #8 square with the ball screw axis. Please make surebearing housing #8 is securely positioned with using Part #9.

Step 6: Now tighten the first nut,Part #23 to put the bearings against the housing. Loosenthe nut and re tighten again to position the bearing properly. Install the second jam nut,Part #23, to secure the first nut also.

Step 7: Rotate the screw manually to ensure there is no jerky motion of the screw or thebearings are not creating any stop and go motion or are completely jammed.

Adjustment of Gibs on the X & Y Axis Slides

The X & Y axis slides have straight gibs. If the slide motion proves out to be sloppy oruneven, adjust the gibs evenly using he set screw provided on the front and side of thecasting.

Step 1: Make sure that the slide is properly lubricated before you start adjusting thescrews.

Step 2: Loosen the gib hex head bolts.

Step 3: Tighten the gib setscrews all the way so there is no table movement.

Step 4: Loosen all setscrews one at a time a quarter of a turn and the check the motion for“fish tailing” and uneven motions to and fro.

Step 5: Adjust all the setscrews until the “fish tailing” movement is eliminated.

Step 6: Tighten the gib hex head bolts. Do NOT exceed 100 in-lb torque.

The tighter the gib the more accurate it will be in motion but the power required to movethe slide may also go up due to the increased sliding friction. Removing and cleaning thegibs before installation is also helpful.

With the gibs property adjusted and the slides lubricated, the torque required to move theslide slowly, should not exceed 15-20% of the maximum motor torque available.



Headstock to Table Realignment

If you have positioned your head at an angle between +/- 0-90º, you will need to realign itto the table by following the steps below”

Step 1: Remove the tool holders and jobs from the table

Step 2: Mount a dial indicator in the spindle of your machine.

Step 3: Loosen the head rotation lock bolts and rotate the head as necessary to realign thespindle so that it is perpendicular to the surface of the table.

Step 4: Sweep the dial indicator 360º to check the results. Make minor adjustments asnecessary.

Step 5: Once the desired results are achieved, lock the mounting bolts and recheck thealignment by sweeping the dial indicator 360º.

In case of a severe accident, contact Smithy for further advice.

Linear Motion Guide & Bearing Maintenance

Unlike sliding guide systems for the X & Y Axes slides, linear motion guides are free fromwear. It requires neither adjustment of the running ways due to uneven wear normaintenance to restore the original accuracy. Sideway systems use a quality of oil for theforced lubrication of the sideways to form and maintain oil films. On the other hand,linear motion (LM) guide systems require only periodical lubrication in a very smallquantity. It contributes to easy, reduced maintenance and to the creation of a cleanworking environment. There are no adjustments required for such bearings and guides.The case of failure of such bearings, replacement is the only cure.

Make sure the linear bearings are not splashed with coolant directly since the lubricatemay be contaminated with coolant which may wash off or emulsify the lubricate; thereby,significantly degrading lubrication's perforamcne. One sign of such case is the increasednoise when the Z-Axis slide moves up and down at high speed. Make sure lubricationsupply is present by checking the ends of the lubrication supply pippin for the proper oilflow.



TOOL HOLDING

OVERVIEW

In milling operations cutters are mounted in a tool holder which is drawn into the spindleby a drawbar system. The CNC-1240 utilize the readily available Bridgeport® R-8 standardtooling . The standard drawbar for R-8 tapered tooling is 7/16 diameter with 20 threads perinch.

Tool Holding Options There are several tool holders that can be used in the spindle of the CNC-1240.

Arbors come in different sizes and lengths with one end tapered to suit the inside spindletaper, in the case of the CNC-1240, an R-8 taper is required. The term arbor is used for ageneral work holding device. Arbors can mount drill chucks, slitting saws, gear cutters andshell end mills. An arbor is secured in place with the drawbar system.

Collets (Spring Collets) are the most commonly used work holding device. They comein a variety of styles and sizes. They are bored to hold a specific diameter. As the collet isdrawn into the spindle of the machine, the spring collet “closes” or “clamps” down on thetool securing it in place.

End Mill Adapters are made specifically to hold end mills. Like arbors they come indifferent sizes with one end tapered to fit the inside spindle taper. End mill adapters arebored to a specific size to hold endmills with a corresponding shank size. End mills aresecured in the adapter by friction and a set screw clamps down on the flat of the end millfor extra security.

Installing the Tooling

Once you have determined the appropriate tooling for your operation, you will need tosecure it in the mill spindle via the drawbar system. The drawbar is located inside theprotective sheet metal housing of the CNC-1240 bed mill.

Step 1: Turn the knurled knob on the right side of the mill head door to access thedrawbar.

7


Figure 7.1 Installing Tooling into the R-8 Spindle

Step 2: The drawbar is secured in place by the drawbar nut, but has a slight movement upand down in the spindle which allows you to easily install your tooling.

Step 3: Insert your tooling into the spindle. NOTE: R-8 tooling has a milled slot on theshank. The slot should be aligned with the pin in the spindle of the machine. The pinprevents your tooling from rotating against the external forces during a cut.

Figure 7.2 The drawbar is located inside the protective sheet metal cover

Step 4: Once the tooling is in place, rotate the drawbar clockwise to install your tooling.Tighten drawbar as noted below.

NOTE: Recommended Tightening Torque for the R8 Collet/Draw Bar

Proper torque settings depend on the application, the condition of the threads, grade of thethread, vibration during machining, types of cut etc. The following table provides ageneral idea about this tightening torque to resist any collet movements. The best practiceis to to check the joint and make sure, from time to time, that the draw bar/collet is stilltight to avoid any unsafe operation.



Table 7.1 Drawbar torque values

To get the best out of the draw bar/collet tightening process, the tightening procedure is recommended as follows:

Step 1: Make sure the threads are not damaged and are free of debris.

Step 2: For a new draw bar and collet, find the thread grade and material, if possible, andthe condition of the thread surface.

Step 3: Tighten the draw bar to 2 to 2.5 times the recommended values provided in theabove table.

Step 4: Loosen the collet and retighten to the specified torque as given in the table.

Step5: Machine a few parts and ensure the collet/draw bar is not loose. Once confirmed,note down the final torque value for future applications also.

Removing Tooling

To remove the tooling, rotate the drawbar counterclockwise. The drawbar nut works as anupward stop when removing your tooling. When you are removing something from thespindle that is held in place with the drawbar, the drawbar will hit the drawbar nut,preventing it from moving upward as the tooling is “pushed” out of the spindle.

THREAD SIZETORQUE FORSAE GRADE 2

PLAIN

TORQUE FORSAE GRADE 2 OIL WAXED

TORQUE FORSAE GRADE 5

PLAIN

TORQUE FORSAE GRADE 5 OIL WAXED

7/16” - 20 32 - 36 ft-lbs 18 - 20 ft-lbs 52- 56 ft-lbs 28 - 32 ft-lbs

Tool Holding


CNC-1240 BED MILL SPECIFICATIONS

Dimension Inch Metric

General Specifications

Length 39.33" 998.98 mm Width 39.75" 1009.65 mm Height 52.33" 1329.18 mm Machine Weight 1175 lbs 532.97 kg Footprint 36" x 24” 914.40 x 609.60 mm Shipping Dimensions 41" x 37" x 48" 1041.40 x 939.80 x 1219.20 mm Shipping Weight 1380 lbs 625.96 kg Maximum Work Capacities

-Drilling mild steel Max dia 0.781" 19.84 mm -Tapping 0.75" 19.05 mm

Specifications

Table Size 40" x 12" 1016 x 304.80 mm Work Cube 22" x 13" x 11.50" 558 x 330.20 x 292.10 mm Maximum Weight on Table 594 lbs 269.43 kg T-Slot Size 5/8" 15.88 mm Slots on Table, Qty. 4 4 Table Travel X Axis 22" 558.80 mm Saddle Travel Y Axis 13" 330.20 mm Head Travel Z Axis 11.5" 292.10 mm Castings Cast Iron Cast Iron Table Surface Precision Ground Precision Ground Ways (X, Y Axis) Dovetail Dovetail Ways (Z Axis) Linear Bearings Linear Bearings Head Swivel + or - 90º + or - 90º

Spindle

Motor HP Rating 2 HP 1.5 KW Maximum Torque 94 in-lb 30 Nm Drive System Geared Belt Geared Belt Minimum Speed 150 RPM 150 RPM

8


Dimension Inch Metric

Maximum Speed 4000 RPM 4000 RPM Positioning Accuracy + or - 0.0005" + or - 0.0127 mm Repeatability 0.00025" 0.00635 mm Quill Diameter 3.15" 80.01 mm Spindle Bearings Angular Contact Angular Contact Spindle to Column 11.5" 292.10 mm Spindle Taper R-8 R-8 R-8

Axes

Stepper Motors (X, Y, Z Axis) 1700 in-oz 1700 in-oz Ball Screws Pre-loaded Pre-loaded

Hardened & Ground Hardened & Ground Ball Screw Size (X Axis) 0.984" 25 mm Ball Screw Size (Y Axis) 0.984" 25 mm Ball Screw Size (Z Axis) 0.787" 20 mm Ball Screw Pitch 0.196" 5 mm Ball Screw Precision P5 P5

Electrical

Power Requirement 220 VAC @ 15 A 220 VAC @ 15 A

Stand Specifications

Stand Footprint 25.20" x 36.50" 640.08 x 927.10 mm Stand Dimensions 25.20" x 36.50" x 37" 640.08 x 927.10 x 939.80 mm Stand Weight 335 lbs 151.95 kg Stand Shipping Weight 462 lbs 209.56 kg Floor Space Required 36" x 60" x 84" 914.40 x 1524 x 2133.60 mm

NOTE: Due to continual design improvements, specifications may change. To view themost up to date specifications, visit www.smithycnc.com.

Specifications


MACHINE PARTS DIAGRAMS

OVERVIEW

This section shows all the necessary parts of the machine. All the diagrams are properlylabellend and numbered. The reference codes and numbers are found on the ReferenceChart after each diagram.

Please have this section ready whenever you have questions, inquiries or in need oftechinical help regarding the machine.

If replacement parts are required, please call us at Toll Free 1-800-476-4849 to talk to aSmithy Techinician.

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nce

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t

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53

DIAG

RAM

5:Table&

BedA

ssembly

ReferenceChart


54

DIA

GRA

M5:

Tabl

e&

Bed

Ass

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fere

nce

Char

t

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DIAG

RAM

5:Table&

BedA

ssembly

ReferenceChart


56

NO

TES:

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ELECTRICAL DIAGRAM & PIN OUTS

OVERVIEW

This section shows all the necessary electrical and pin out diagram of the machine. Thediagram is properly labellend and numbered. The reference codes and numbers are foundon the Reference Chart after each diagram.

Please have this section ready whenever you have questions, inquiries or in need oftechinical help regarding the machine.

If replacement parts are required, please call us at Toll Free 1-800-476-4849 to talk to aSmithy Techinician.

10


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ElectricalDiagram&

PinO

utsReference

Chart


60

Elec

trica

lDia

gram

&Pi

nO

uts

Refe

renc

eCh

art

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Free

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61

Documents

SmithyCNC 1240 Manual 2008 - Detroit Machine Toolsserver2.smithy.com/media/pdf/SmithyCNC 1240 Manual 2008.pdf · ... Protective Sheetmetal Cover, ... Our friendly service technicians